300MM single stackable film frame carrier

ABSTRACT

An interlockable film frame carrier has central and peripheral portions for securely storing a film frame, the film frame supporting a film, a semiconductor wafer disposed on the film. The central portion has structure for supporting the semiconductor wafer and for allowing access to a lower surface of the stored film frame. The peripheral portion of the film frame carrier includes structure for supporting a peripheral portion of the film frame and matable stacking members. When the film frame is stored, two film frame carriers are interlocked by mating the stacking members. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.

CROSS-REFERENCES TO RELATED APPLICATIONS

[0001] This application claims priority under 35 U.S.C. § 119 (e) to, and hereby incorporates by reference, U.S. Provisional Application No. 60/305,639, filed Jul. 15, 2001.

BACKGROUND

[0002] 1. Field of the Invention

[0003] This invention relates to carriers for semiconductors. In particular, this invention relates to single, stackable film frame carriers for semiconductors.

[0004] 2. Background of the Invention

[0005] The present invention relates to thermal-formed, stackable carriers for film frames. Film frames are generally stainless-steel with a film extending across the film frame. The film has an adhesive on one side thereof. After being processed, a round semiconductor wafer is placed on the film. After being positioned on the film, the semiconductor wafer may be sectioned into individual pieces (e.g., chips), transported for further processing, or stored. The semiconductor processing industry is using larger and thinner wafers. These larger and thinner wafers present processing, transportation, and storage handling problems due to their greater fragility. To this end, conventional wafer carriers have often proven unacceptable for these larger and thinner wafers. The additional support provided by film frames reduces damages to wafers during these activities. Thus, film frames are being utilized to a much greater extent for transporting wafers and integrated circuit chips. However, there is a nonetheless need for a carrier to secure film frames and protect the wafers from damage during processing, transportation and storage. There is a further need to store and protect wafers being borne on film frame carriers in a space efficient manner.

SUMMARY OF THE INVENTION

[0006] The present film frame carrier needs many of the aforementioned needs. One embodiment of the present film frame carrier includes a central portion and a peripheral portion. The central portion is configured to provide a platform and a trough. The platform provides protection for the semiconductor wafer. The peripheral portion is configured to provide an access. The access and trough allow the film frame to be disposed and removed from the central portion of the present film frame carrier. When disposed in the present film frame carrier, a lower surface of the film frame rests on a ledge defined in the frame carrier peripheral portion. When two of the present film frames are mated by being interlocked, a lower surface of the trough contacts an upper surface of the film frame to secure the film frame in place. The mated film frames are further interlocked by being frictionally held in place by mated male and female stacking members.

[0007] The invention described and disclosed herein is a stackable film frame carrier configured to securely hold individual film frames in a horizontal orientation.

[0008] Stacking and interlocking the present film frame carriers with film frames disposed therebetween provides for economy in that more semiconductor wafers can be shipped or stored per unit volume. The practice of stacking and interlocking (mating) the film frame carriers with interposed film frames therebetween also decreases the likelihood that the film frame carriers will become dislodged thereby exposing the semiconductor wafer therein to damage.

[0009] Horizontally stacking film frame carriers provides stabilization of the film frames due to the effects of gravity.

[0010] Hence, film frame carriers configured to be horizontally stacked after being loaded with semiconductor wafers offer enhanced economy and a greatly decreased likelihood of wafer and chip damage during handling, storage, and transportation.

[0011] It is one advantage of the present carrier that wafers may be stored, transported, and processed in a stable horizontal orientation.

[0012] It is another advantage of the present carrier that wafers stored, handled, and transported horizontally therewithin are less susceptible to damage.

[0013] It is yet another advantage that the present carrier may be stackingly interlocked when nested in the manner disclosed herein.

[0014] Additional objects, advantages, and features of various embodiments of the present invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following or may be learned by practice of the invention. The objects and advantages of various embodiments of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015]FIG. 1 is a perspective view of the present single stackable film frame carrier;

[0016]FIG. 2 is a plan view of a stacked pair of the film frame carriers of FIG. 1;

[0017]FIG. 3 is a cross-sectional view of the film frame carriers of FIG. 2 taken along lines 3-3; and

[0018]FIG. 4 is an enlarged partial cross-sectional view of the film frame carriers of FIG. 3.

[0019] It is understood that the above-described figures are only illustrative of the present invention and are not contemplated to limit the scope thereof

DETAILED DESCRIPTION OF THE INVENTION

[0020] Any references to such relative terms as inboard and outboard, upper and lower, and the like, are intended for convenience of description and are not intended to limit the present invention or its components to any one positional or spatial orientation.

[0021] One embodiment of the present single stackable film frame carrier is shown in the figures generally at 100. One suitable material for making the present film frame carrier is polyethylene terephthalate glycol between about 0.075 and 0.125 inch in thickness. However, it is recognized that several materials and thicknesses may be suitable for other embodiments. A conductor such as carbon may also be present in the synthetic resin used to make the present film frame carrier, for example, if static electricity dissipation is desired. The present film frame carrier is substantially unitary (or otherwise integral), having been thermally formed or vacuum molded from a single sheet of synthetic resin in one embodiment. However, the present film frame carrier may be envisioned as including a central portion 106 and a peripheral portion 108. The central portion 106, in turn, may be envisioned as including a platform 112 having an upper surface 114 and a trough 116 with an upper surface 118 an outboard surface 119, and a lower surface 120. In the embodiment depicted, the platform 112 is generally circular and the trough 116 is concentrically disposed about the platform 112.

[0022] Relevant features of the peripheral portion 108 include four larger exterior sides 121, four smaller exterior sides 122, a plurality of (e.g., four) inner accesses 124, a plurality of (e.g., four) ledges 126, a supporting structure such as an inner rim 128, a plurality of (e.g., four) male stacking members 130, a plurality of (e.g., four) female stacking members 132, respective first and second outer rims 134 and 136, and a flange 138. The male and female stacking members are embodiments of the nestable stacking members of this invention. Each inner access 124 displays an upper surface 146 and an inboard surface 148. The inner accesses 124 generally open into the trough 116 and are generally disposed at about 90 degrees with respect to each other. The inner accesses 124 are configured to allow access to the lower side of a film frame stored in the present frame carrier. Each ledge 126 displays an upper surface 152 and an inboard surface 154. The ledges 126 are formed in the peripheral portion 108 and are generally spaced apart at about 90 degrees and are generally intermediate between the inner accesses 124. The ledges 126 and troughs 116 are also considered as nestable stacking members when two or more of the present frame carriers are stacked in a manner such as more fully described below. Each inner rim 128 displays an inboard surface 158 and is disposed between an inner access 124 and an adjacent ledge 126. Each male stacking member 130 displays opposed inner and outer peripheral surfaces 162 and 164 and opposed upper and lower surfaces 166 and 168. The male stacking members 130 generally extend above the remainder of the peripheral portion 108. Two of the male stacking members 130 are spaced apart proximate each of the larger exterior sides 121. Each female stacking member 132 is disposed proximate generally opposite, and opens toward, larger sides 121 and displays generally opposing upper and lower surfaces 172 and 174 and opposing outward and inboard surfaces 176 and 178. The female stacking members 132 are formed in the peripheral portion 108 and are disposed in pairs proximate the larger sides 121, which are not proximate the male stacking members 130. The first outer rim 134 displays an outboard surface 182 and an upper surface 184. The relevant features of the second outer rim 136 include an inner surface 188 and a lower surface 190. The second outer rim 136 extends outboard from, and below, the first outer rim 134. The flange 138 extends generally orthogonally from a lower tip of the second outer rim 136.

[0023] A film frame 194 stored in the present frame carrier may be a substantially circular rigid (e.g., steel) member to which a film 196 is attached. An adhesive coating is usually present on one side of the film 196. A semiconductor wafer 198 is positioned on the film 196 and held in place by the adhesive coating. Functionally, the film frame 194, and semiconductor wafer 198 positioned on the film 196, are positioned within the peripheral portion 108 of the present frame carrier. The semiconductor 198 is positioned such that the semiconductor wafer 198 extends over the upper surface 114 of the platform 112. A peripheral portion of a lower surface 202 of the film frame 194 rests on the upper surface 152 and abuts the inboard surface 154 of the ledge 126. The accesses 124 enable access of digits from a person or robot to place the film frame 194 (and semiconductor 198) in the present frame carrier by providing access to the underside 202 of the film frame 194, thereby allowing the film frame 194 to be lowered into, or lifted from, the present film frame 100 either manually or robotically.

[0024] When two of the present frame carriers 100 are mated, the lower surface 120 of the trough 116 contacts an upper surface 204 of the film frame 194, thereby securing the film frame 194 in place. Also, as two of the present film frame carriers 100 are being mated, the male stacking members 130 of the lower frame carrier 100 are forced into the male stacking members 130 of the upper frame carrier 100, thereby sliding the peripheral outer surface 164 of the lower frame carrier against the peripheral inner surface 162 of the upper frame carrier to some extent. As the male stacking members are being mated, the female stacking member outboard surface 176 of the lower frame carrier is slid against the female stacking member inboard surface 178 of the upper frame carrier to some extent. As the male and female members are being interlocked, the inner surface 188 and lower surface 190 of the upper frame second outer rim contacts the outboard surface 182 and upper surface 184 of the lower frame carrier first outer rim. When two of the present frame carriers 100 are mated as described above, they may be further secured by placing rivets through adjacent, mated female stacking members 132, e.g., at points 206 and through adjacent mated male stacking members 130, e.g., at points 208. While the above description describes mating only two of the present film carriers, obviously any desired number may be mated in this fashion.

[0025] It should be understood that a person of ordinary skill in the art would readily comprehend and adapt the present frame carrier so that a plurality of the film frames may be secured between two of the present, nested frame carriers. It should be further understood that a person of ordinary skill the art would readily comprehend that a semiconductor wafer, without a film frame, could be disposed and secured within to the present, nested frame carriers as well.

[0026] Because numerous and modifications of this invention may be made without departing from the spirit thereof, the scope of the invention is not to be limited to the embodiments illustrated and described. Rather, the scope of the invention is to be determined by the appended claims and their equivalents. 

What is claimed is:
 1. An interlocking carrier for securing a film frame, the film frame supporting a film, a semiconductor wafer disposed on the film, the carrier comprising: a central portion; and a peripheral portion disposed about the central portion and comprising structure supporting a peripheral portion of the film frame and a plurality of nestable stacking members.
 2. The interlocking carrier of claim 1, the support for the semiconductor wafer including a generally circular platform.
 3. The interlocking carrier of claim 1, the central portion configured to provide a platform and a trough generally concentrically disposed about the platform.
 4. The interlocking carrier of claim 3, the trough displaying a lower surface contacting an upper surface of the film frame when said interlocking carrier is mated with another substantially identical interlocking carrier.
 5. The interlocking carrier of claim 1, at least one of the nestable stacking members including a male stacking member.
 6. The interlocking carrier of claim 1, at least one of the nestable stacking members including a female stacking member.
 7. The interlocking carrier of claim 1, the peripheral portion further comprising a ledge, said peripheral portion ledge cooperating with a trough defined in the central portion to interlock the carrier with another stacked and substantially identical carrier.
 8. The interlocking carrier of claim 1, in which four nestable stacking members are present.
 9. The interlocking carrier of claim 8, the four nestable stacking members in a male configuration.
 10. The interlocking carrier of claim 8, the four nestable stacking members in a female configuration.
 11. The interlocking carrier of claim 8, in which the four nestable stacking members are disposed in pairs proximate generally opposite peripheral portion sides.
 12. The interlocking carrier of claim 1, the peripheral portion structure supporting a peripheral portion of the film frame comprising a ledge.
 13. The interlocking carrier of claim 1, the peripheral portion further defining structure for providing access to an underside of the film frame when the film frame is disposed in the interlocking carrier.
 14. A method of manufacturing an interlocking carrier for securing a film frame, the film frame supporting a film, a semiconductor wafer disposable on the film, the method comprising; providing a synthetic resin; forming a central portion and a peripheral portion in the synthetic resin, the central portion, the peripheral portion disposed about the central portion and comprising structure for supporting a peripheral portion of the film frame and a plurality of nestable stacking members.
 15. The method of claim 14, in which the central portion and peripheral portion are thermally formed.
 16. The method of claim 14, in which the central portion and peripheral portion are formed by vacuum molding.
 17. The method of claim 14, in which the formed central portion includes a generally circular platform.
 18. The method of claim 17, in which the formed central portion further includes a trough generally concentrically disposed about the circular platform.
 19. The method of claim 14, in which the formed central portion structure for supporting a peripheral portion of the film frame includes a ledge.
 20. The method of claim 14, in which the formed central portion nestable stacking members include a plurality of male members.
 21. The method of claim 20, in which the formed male members are disposed in pairs proximate generally opposite sides of the central portion.
 22. The method of claim 14, in which the formed central portion nestable stacking members include a plurality of female members.
 23. The method of claim 22, in which the formed female members are disposed in pairs proximate generally opposite sides of the central portion.
 24. A method of storing a film frame, the film frame configured to support a film and a semiconductor wafer disposed on the film, the method comprising: disposing the film frame within a peripheral portion of a first film frame carrier such that a peripheral portion of the film frame is supported by a peripheral portion support structure and such that the semiconductor wafer extends over a first film frame carrier platform; and interlocking a second film frame carrier to the first film frame carrier by mating a stacking member of the first frame carrier to a stacking member of a second frame carrier, the second film frame carrier substantially identical to the first film frame carrier.
 25. The method of claim 24, in which interlocking the second film frame carrier to the first film frame carrier includes contacting to a lower surface of the second film frame carrier to the film frame.
 26. The method of claim 24, the first and second frame carrier each comprising a plurality of stacking members disposed proximate generally opposite sides of said first and second frame carriers and in which interlocking the second and first film frame carriers includes mating each of said plurality of said first frame stacking members with corresponding ones of the second frame stacking members.
 27. The method of claim 26, the first and second frame carrier stacking members having a male configuration and in which interlocking said first and second film frame carriers includes mating said stacking members having a male configuration.
 28. The method of claim 26, the first and second frame carrier stacking members having a female configuration and in which interlocking said first and second film frame carriers includes mating said stacking members having a female configuration.
 29. The method of claim 24, in which the peripheral portion of the film frame is supported by a ledge.
 30. The method of claim 24, in which the first and second film frame peripheral portions define structure for accessing a lower surface of the film frame and in which disposing the film frame within a peripheral portion of the first film frame character includes lowering the film frame and withdrawing a digit from beneath the film frame through the accessing structure. 